Stator assembly and motor

Abstract

The present application provides a stator assembly and a motor. The stator assembly comprises a bridge (1) and at least two stator elements, the stator element comprises a core (2) and a skeleton (3), the skeleton (3) is at least partially wrapped outside the core (2), and the skeletons (3) of two adjacent stator elements are fixedly connected by the bridge (1). According to the stator assembly of the present application, it is possible to avoid slotting on the stator core to fix the bridge, which will not affect the magnetic circuit and effectively improve the motor performance.

Description

Technical Field

[0001] The present application relates to the technical field of motors, and in particular to a stator assembly and a motor. Background Art

[0002] The stator for a four-pole motor may include two C-shaped cores arranged on opposite sides of the rotor. Using a C-shaped core allows for more packing of the stator and is easier to wind than a conventional single full-round core.

[0003] A motor stator is disclosed in the related art, the stator comprising a plurality of stator elements, each stator element comprising a C-shaped core, the C-shaped core having two magnetic poles, each magnetic pole of each stator element being fixed to the magnetic pole of an adjacent stator element by a bridge, the bridge being formed of a non-magnetic material and molded onto the magnetic pole. In the motor stator, since the bridge is fixed to the stator magnetic pole, a groove or a protrusion needs to be provided on the core punching sheet near the tooth shoe portion for fixing, which will affect the magnetic circuit and thus affect the motor performance. Summary of the invention

[0004] Therefore, the technical problem to be solved by the present application is to provide a stator assembly and a motor that can avoid slotting on the stator core to fix the bridge piece, will not affect the magnetic circuit, and effectively improve the motor performance.

[0005] In order to solve the above problems, the present application provides a stator assembly, including a bridge and at least two stator elements, the stator element includes a core and a skeleton, the skeleton is at least partially wrapped around the core, and the skeletons of two adjacent stator elements are fixedly connected by the bridge.

[0006] Preferably, the bridge member and the frame are formed as an integral structure.

[0007] Preferably, the bridge member and the frame are injection molded into an integral structure.

[0008] Preferably, the injection-molded matching structure between the frame and the bridge member is a concave-convex matching structure.

[0009] Preferably, a groove for injection molding is provided on the frame, and the connecting end of the bridge piece is injection molded in the groove.

[0010] Preferably, the groove includes a first groove and a second groove, the first groove extends along a first direction, the second groove extends along a second direction, and a preset angle is formed between the first direction and the second direction.

[0011] Preferably, the first groove and the second groove are communicated with each other.

[0012] Preferably, the first groove and the second groove are both arranged on the end surface of the connecting end of the skeleton.

[0013] Preferably, the first groove is arranged on the end surface of the connecting end of the frame and extends along the length direction of the end surface of the connecting end, and the second groove extends from the end surface of the connecting end of the frame in a direction away from the bridge member.

[0014] Preferably, there are at least two second grooves, which are spaced apart along the extending direction of the first groove.

[0015] Preferably, at least one second groove is arranged at a first end portion of the first groove, and at least one second groove is arranged at a second end portion of the first groove.

[0016] Preferably, the cross-sectional opening of the first groove shrinks along a direction away from the groove bottom of the first groove.

[0017] Preferably, the groove is arranged on the end surface of the connecting end of the frame and extends along the length direction of the end surface of the connecting end, and a protrusion or a depression is arranged on the inner wall of the groove.

[0018] Preferably, a mounting groove is provided on the bridge member, and a Hall sensor is installed in the mounting groove.

[0019] Preferably, the bridge is made of a non-magnetic material.

[0020] Preferably, the core is a C-shaped core.

[0021] According to another aspect of the present application, a motor is provided, including a stator assembly and a rotor assembly, wherein the stator assembly is the above-mentioned stator assembly.

[0022] The stator assembly provided in the present application includes a bridge and at least two stator elements, the stator element includes a core and a skeleton, the skeleton is at least partially wrapped outside the core, and the skeletons of two adjacent stator elements are fixedly connected by a bridge. The stator assembly in the present application connects the segmented cores together by a bridge, which can reduce the difficulty of the stator and rotor centering installation and ensure the air gap accuracy. The stator assembly uses a bridge to connect the skeleton to achieve a fixed connection between the segmented cores, and there is no need to slot the core, so it will not affect the motor magnetic circuit and can effectively improve the motor performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 This is a schematic structural diagram of a stator assembly according to an embodiment of the present application;

[0024] Figure 2 This is a schematic diagram of the three-dimensional structure of a stator assembly according to an embodiment of the present application;

[0025] Figure 3 A schematic diagram of the structure of a stator element of a stator assembly according to an embodiment of the present application;

[0026] Figure 4 This is a schematic diagram of the skeleton structure of a stator assembly according to an embodiment of the present application;

[0027] Figure 5 This is a schematic diagram of the skeleton structure of a stator assembly according to an embodiment of the present application.

[0028] The reference numerals are as follows:

[0029] 1. Bridge; 2. Core; 3. Skeleton; 4. First slot; 5. Second slot; 6. Mounting slot; 7. Hall sensor; 8. Rotor assembly; 9. Winding. DETAILED DESCRIPTION

[0030] See also Figures 1 to 5 As shown, according to an embodiment of the present application, the stator assembly includes a bridge 1 and at least two stator elements, the stator element includes a core 2 and a skeleton 3, the skeleton 3 is at least partially wrapped around the core 2, and the skeletons 3 of two adjacent stator elements are fixedly connected by the bridge 1.

[0031] The stator assembly in the present application connects the segmented cores together through a bridge piece, which can reduce the difficulty of stator and rotor centering installation and ensure air gap accuracy. Single-phase motors require special air gap design to ensure that the motor can self-start. Accurate stator and rotor centering can ensure that the motor has a more stable self-starting capability.

[0032] The stator assembly uses a bridge 1 and a frame 3 to achieve fixed connection between the segmented cores. There is no need to slot the core 2, and the core tooth width will not be changed, so the motor magnetic circuit will not be affected, and the motor performance can be effectively improved.

[0033] The number of stator elements and bridge members 1 in the present application is multiple, wherein two adjacent cores 2 of different stator elements are fixedly connected by a bridge member 1, so that each stator element can be fixedly connected together by the bridge member 1 to form an integral structure.

[0034] The core 2 includes a plurality of magnetic materials such as silicon steel sheets. In this embodiment, the core 2 is a C-shaped core, including a yoke and two teeth extending from opposite end faces of the yoke. Each tooth extends toward the shaft hole in the middle of the stator assembly. The end of each tooth is called a tooth shoe. The C-shaped core can reduce the volume of the stator assembly, reduce the weight of the stator assembly, and reduce the difficulty of winding.

[0035] Each frame 3 is wrapped around the teeth of the core 2, and a winding 9 is wound around the outside of each frame 3. A pair of windings 9 on each stator element are connected in parallel, and then connected in parallel with the windings 9 on other stator elements to form a whole single-phase winding.

[0036] In this embodiment, there are two stator elements and two bridges 1. The two stator elements are arranged with tooth boots facing each other and connected and fixed together by two bridges 1. More specifically, the first bridge fixes the frame surrounded by the first tooth portion of the first stator element to the frame wrapped on the first tooth portion of the second stator element, and the second bridge fixes the frame surrounded by the second tooth portion of the first stator element to the frame wrapped on the second tooth portion of the second stator element. Each bridge 1 is thus bridged between two stator elements.

[0037] In this embodiment, the bridge member 1 and the frame 3 are formed into an integral structure, which can ensure the connection strength between the bridge member 1 and the frame 3 and reduce the difficulty of combining the bridge member 1 and the frame 3.

[0038] In one embodiment, the bridge 1 and the frame 3 are injection molded into an integrated structure. Generally speaking, the frame 3 is an injection molded structure, and the injection molded contact surface of the bridge 1 is set as a plastic frame. The bridge 1 is also made of plastic material, so the bonding is good, which can ensure that a good injection molded structure is formed between the bridge 1 and the frame 3, and the bonding strength between the two is ensured, so that the bridge 1 is not easy to loosen, and the stability and reliability of the overall structure of the stator assembly are ensured.

[0039] In one embodiment, the injection molding matching structure between the skeleton 3 and the bridge member 1 is a concave-convex matching structure, which can not only form an effective injection molding space to ensure the injection molding combination between the skeleton 3 and the bridge member 1, but also utilize the concave-convex matching structure formed by the injection molding space, so that after the skeleton 3 and the bridge member 1 are injection molded together, the relative displacement between the skeleton 3 and the bridge member 1 is limited by the concave-convex structure, thereby ensuring the assembly stability between the two and avoiding loosening.

[0040] The structural design of the bridge member 1 is relatively friendly to injection molding and does not require high precision of the mold itself. Therefore, even if slight material loss occurs during the injection molding process, it will not affect the bonding strength between the bridge member 1 and the frame 3.

[0041] In one embodiment, a groove for injection molding is provided on the skeleton 3, and the connecting end of the bridge 1 is injection molded in the groove. The groove for injection molding is provided on the skeleton 3 because the skeleton 3 is firstly injection molded on the core 2, and the bridge 1 is then injection molded as a whole with the skeleton 3. Therefore, the groove on the skeleton 3 can be used to limit the injection molding of the bridge 1, and the skeleton 3 can be used to replace part of the mold core, thereby saving the injection molding cost and reducing the difficulty of injection molding.

[0042] In other embodiments, protrusions may also be provided on the skeleton 3 , and when the bridge member 1 is injection molded on the skeleton 3 , the protrusions on the skeleton 3 can be molded inside the bridge member 1 , thereby achieving a tight combination between the skeleton 3 and the bridge member 1 .

[0043] In one embodiment, the groove includes a first groove 4 and a second groove 5, the first groove 4 extends along a first direction, the second groove 5 extends along a second direction, and a preset angle is formed between the first direction and the second direction. Since the first groove 4 and the second groove 5 extend in different directions, after the bridge 1 and the frame 3 are combined by injection molding, the combination of the bridge 1 and the frame 3 can be limited from different directions, which effectively improves the combination strength of the bridge 1 and the frame 3.

[0044] In one embodiment, the first groove 4 and the second groove 5 are connected. When the bridge member 1 is injection molded on the skeleton 3, since the first groove 4 is connected with the second groove 5, as long as the injection material is poured into one of the grooves, it can flow along the groove and enter the first groove 4 and the second groove 5 at the same time, which saves the number of injection ports required in the injection molding process, reduces the difficulty of injection molding, and saves the injection molding cost.

[0045] In one embodiment, the first groove 4 and the second groove 5 are both arranged on the connecting end surface of the skeleton 3, that is, the openings of the first groove 4 and the second groove 5 are both located on the connecting end surface of the skeleton 3 connected to the bridge member 1, which not only facilitates the injection molding of the bridge member 1 and the skeleton 3 together, but also can ensure that the injection molding material of the bridge member 1 is in full contact with the skeleton 3, thereby reducing the difficulty of injection molding and improving the bonding strength after injection molding.

[0046] In one embodiment, the first groove 4 is arranged on the end face of the connecting end of the skeleton 3 and extends along the length direction of the end face of the connecting end. The second groove 5 extends from the end face of the connecting end of the skeleton 3 in a direction away from the bridge member 1, which can form injection molding limits in different directions for the bridge member 1 and provide better structural stability.

[0047] In this embodiment, the length direction of the end face of the connection end is also the axial direction of the shaft hole. Since the skeleton 3 is a square frame structure, the frame of the skeleton 3 located away from the shaft hole is used for connection with the bridge member 1.

[0048] In one embodiment, there are at least two second grooves 5, which are spaced apart along the extension direction of the first groove 4, and at least two injection molding joints can be formed in the second direction, thereby combining with the injection molding material in the first groove 4 to form a more stable connection between the bridge 1 and the skeleton 3.

[0049] In one embodiment, at least one second groove 5 is arranged at the first end portion of the first groove 4, and at least one second groove 5 is arranged at the second end portion of the first groove 4, so that the injection molding structure located in the first groove 4 can be limited from both ends of the first groove 4, so that the injection molding material located in the first groove 4 will not escape along the first groove 4, thereby improving the stability of the connection structure between the stator elements of the stator assembly.

[0050] In one embodiment, the cross-sectional opening of the first groove 4 shrinks in a direction away from the bottom of the first groove 4, and the cross-sectional shape is, for example, a dovetail shape, a trapezoidal shape, an arc shape, etc., which can limit the injection molding material entering the first groove 4 and prevent the injection molding material from escaping from the opening of the first groove 4, thereby forming an all-round limit on the combination of the bridge 1 and the skeleton 3, avoiding relative displacement between the two in any direction, and ensuring assembly stability.

[0051] In one embodiment, the first groove 4 may also extend along the end surface of one axial end of the rotating shaft hole of the skeleton 3 toward the other end, and the first groove 4 does not penetrate the skeleton 3 in the axial direction.

[0052] In one embodiment, the groove is provided on the end surface of the connection end of the frame 3 and extends along the length direction of the end surface of the connection end, and a protrusion or a depression is provided on the inner wall of the groove. In this embodiment, only one groove for injection molding is provided on the frame 3. In order to prevent the bridge 1 from protruding from the groove after the injection molding is completed, a protrusion or a depression is added to the inner wall of the groove. After the injection molding enters the groove, the protrusion or the depression can enhance the bonding force between the bridge 1 and the frame 3, and effectively prevent the bridge 1 from being separated from the frame 3. The above-mentioned protrusions are, for example, a plurality of convex points or bumps, and the depressions are, for example, strip grooves, spherical grooves, etc.

[0053] In one embodiment, the bridge member 1 is provided with a mounting groove 6, in which a Hall sensor 7 is installed. The mounting groove 6 is provided along the axial direction of the shaft hole and is used to install the Hall sensor. The Hall sensor is positioned in the mounting groove 6 of one of the bridge members 1.

[0054] The position of the mounting slot 6 on the bridge member 1 can be designed to more accurately fix the position of the Hall sensor. The Hall sensor has an optimal position in the motor to ensure accurate synchronization of the excitation and the rotor position, thereby ensuring stable operation of the controlled motor. The position of the Hall sensor can be more accurately positioned by limiting the position of the Hall element bracket and the mounting slot 6.

[0055] In one embodiment, the bridge member 1 is made of non-magnetic material, so as to prevent the bridge member 1 from affecting the magnetic circuit of the motor and ensure the performance of the motor.

[0056] In one embodiment, each frame 3 is provided with two holes for fixing the wiring terminals. The wiring terminals are made of conductive non-magnetic metal material. The hole positions and terminal sizes are matched by transition fit, and the gaps are filled with adhesive for further fixing.

[0057] The assembly process of the stator assembly is as follows:

[0058] The stator is manufactured by assembling each stator element. The stator element needs to first mold the skeleton 3 on the teeth of the core 2 to form a stator element without windings 9, such as Figure 3 As shown, the upper part thereof needs to be fixed with a connecting terminal, and then the winding 9 is wound on the frame 3, and the end of the wire is fixed on the connecting terminal.

[0059] After the stator elements are assembled, a pair of stator elements are placed in a mold (not shown in the figure), which includes a series of positioning structures for aligning the two stator elements. In particular, the mold includes a core column whose outer surface is consistent with the shape of the tooth shoe surface of the core, so that the tooth shoe can be close to the core column to ensure accurate centering and better define the stator-rotor air gap. In addition, the slots of the stator yoke can also cooperate with the mold positioning structure to ensure accurate centering.

[0060] After the stator elements are placed in the mold and aligned, plastic is injected into the mold to form a bridge 1. The bridge 1 has a matching structure of grooves or protrusions in the first direction and the second direction, which can more stably fix the two stator elements together and prevent them from loosening due to poor bonding. If some material escapes during the injection molding process, it will not affect the motor's motion performance. Some external material can be scraped off with a knife.

[0061] After the entire stator assembly is completed Figure 2 As shown, the motor can be assembled more easily. The stator assembly can be accurately positioned by matching the yoke slot of the stator element with the corresponding slot on the motor housing, and the stator assembly can be further fixed by adhesive. At the same time, the rotor is also fixed by the housing. In this way, only the accuracy of the housing and the stator-rotor fixing part is required to ensure the accuracy of the stator-rotor centering and air gap, thus avoiding more tolerances.

[0062] According to an embodiment of the present application, the motor includes a stator assembly and a rotor assembly 8, wherein the stator assembly is the above-mentioned stator assembly. The rotor assembly 8 includes a rotating shaft and a permanent magnet, wherein the permanent magnet is fixed outside the rotating shaft.

[0063] It is easy for those skilled in the art to understand that, under the premise of no conflict, the above-mentioned advantageous methods can be freely combined and superimposed.

[0064] The above are only preferred embodiments of the present application and are not intended to limit the present application. Any modifications, equivalent replacements and improvements made within the spirit and principles of the present application shall be included in the protection scope of the present application. The above are only preferred implementations of the present application. It should be pointed out that for ordinary technicians in this technical field, several improvements and variations can be made without departing from the technical principles of the present application, and these improvements and variations should also be regarded as the protection scope of the present application.

Claims

1. A stator assembly, characterized in that, it includes a bridging member (1) and at least two stator elements. The stator elements include a core (2) and a skeleton (3). The skeleton (3) at least partially wraps around the core (2). The skeletons (3) of two adjacent stator elements are fixedly connected through the bridging member (1); the bridging member (1) and the skeleton (3) are formed into an integral structure. The injection molding fit structure between the skeleton (3) and the bridging member (1) is a concave-convex fit structure. Grooves for injection molding are provided on the skeleton (3). The skeleton (3) is first injection molded on the core (2), and the connecting end of the bridging member (1) is later injection molded into the groove; the groove includes a first groove (4) and a second groove (5). The first groove (4) is provided on the end face of the connecting end of the skeleton (3) and extends along the length direction of the end face of the connecting end. The second groove (5) extends from the end face of the connecting end of the skeleton (3) in a direction away from the bridging member (1); the first groove (4) extends in a first direction, the second groove (5) extends in a second direction, and a preset angle is formed between the first direction and the second direction; the first groove (4) and the second groove (5) are communicated.

2. The stator assembly according to claim 1, characterized in that, the bridging member (1) and the skeleton (3) are injection molded into an integral structure.

3. The stator assembly according to claim 1, characterized in that, both the first groove (4) and the second groove (5) are provided on the end face of the connecting end of the skeleton (3).

4. The stator assembly according to claim 1, characterized in that, there are at least two second grooves (5), which are arranged at intervals along the extending direction of the first groove (4).

5. The stator assembly according to claim 4, characterized in that, at least one of the second grooves (5) is provided at the first end of the first groove (4), and at least one of the second grooves (5) is provided at the second end of the first groove (4).

6. The stator assembly according to claim 1, characterized in that, the cross-sectional opening of the first groove (4) shrinks along the direction away from the bottom of the first groove (4).

7. The stator assembly according to claim 1, characterized in that, the groove is provided on the end face of the connecting end of the skeleton (3) and extends along the length direction of the end face of the connecting end. Protrusions or depressions are provided on the inner wall of the groove.

8. The stator assembly according to claim 1, characterized in that, an installation groove (6) is provided on the bridging member (1), and a Hall sensor (7) is installed in the installation groove (6).

9. The stator assembly according to claim 1, characterized in that, the bridging member (1) is made of non-magnetic material.

10. The stator assembly according to claim 1, characterized in that, the core (2) is a C-shaped core.

11. A motor, including a stator assembly and a rotor assembly (8), characterized in that, the stator assembly is the stator assembly according to any one of claims 1 to 10.

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